Moving headboard trailer ejector and floor cleaning apparatus

ABSTRACT

The present invention relates to a detachably attachable moving headboard trailer ejector and floor cleaning apparatus for use with a self-unloading trailer having a front end, a rear end, side walls, and either a reciprocating slat conveyor floor or a conveyor belt floor. The invention comprises, in one embodiment, a base, a panel sweeper, one or more panel sweeper support members, a means for traversing the panel sweeper, a tether bar, side flanges, and a base flange. In use, the invention is placed in the front end of a self-unloading trailer and the trailer is loaded with material; when material is ejected from the trailer, the invention transverses or “travels” along the top of the moving floor and pushes the material out of the trailer&#39;s back end. The rubber flanges ensure a snug fit within the trailer and keep post ejection residual material at a minimum.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/465,650, filed May 7, 2012, now U.S. Pat. No. 9,126,520,issued Sep. 8, 2015, which is a continuation-in-part of and claims thebenefit of U.S. patent application Ser. No. 12/184,470, filed Aug. 1,2008, now abandoned, both of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to devices for ejecting bulkmaterials from trailers. More particularly, the present inventionrelates to a detachably attachable moving headboard trailer ejector andfloor cleaning apparatus for use with a self-unloading trailer having afront end, a rear end, side walls, and either a reciprocating slatconveyor floor or a conveyor belt floor.

2. Description of the Related Art

Many bulk commodities and aggregates are transported throughout theUnited States by various types of trailers, including transportsemi-trailers. Materials commonly moved include, but are not limited to,dirt, sand, rock, grain, etc. A truck operator is paid to move materialfrom one location to another—the more material an operator can move in agiven period of time, the more profitable the operator's business willbe.

Many transport trailers used by operators are of the “self-unloading”type. Self-unloading trailers use one of several forms of “movingfloors” to eject material from the trailer. Moving floors come invarious forms including, but not limited to, reciprocating slat floorsand conveyor belt floors. By their automation, these floorssubstantially decrease the time required to eject material from trailerscompared to manual ejection methods. One time consuming drawback of amoving floor, however, is that after ejecting transported material fromthe trailer, some amount of residual transported material often remainson the trailer floor—material that must be manually swept or shoveledout of the trailer. Removing residual material from a trailer takestime, which increases the total transport time and reduces theoperator's profit.

Heretofore there has not been available a moving headboard trailerejector system or apparatus with the advantages and features of thepresent invention.

SUMMARY OF THE INVENTION

The present invention relates to a detachably attachable movingheadboard trailer ejector and floor cleaning apparatus for use with aself-unloading trailer having a front end, a rear end, side walls, andeither a reciprocating slat conveyor floor or a conveyor belt floor. Theinvention comprises, in one embodiment, a base, a panel sweeper, one ormore panel sweeper support members, a means for traversing the panelsweeper, a tether bar, side flanges, and a base flange.

In use, the invention is placed in the front end of a self-unloadingtrailer and the trailer is loaded with material; when the moving flooris activated and material is ejected from the trailer, the invention“travels” or transverses along the moving floor and pushes the materialout of the trailer's back end. The rubber flanges ensure a snug fitwithin the trailer and keep post ejection residual material at aminimum. After ejection is complete, the apparatus may be pushed backinto place or pulled back into place via the tether bar. The inventionmay be used with most self-unloading trailers and does not requireretrofitting of trailers for proper use. The means for traversing thepanel sweeper may include a stationary door, a hinged door, ahorizontally sliding panel, or a vertically sliding panel and gives theoperator access to the trailer area behind the apparatus without theneed to climb over the apparatus and risk injury.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and includeexemplary embodiments of the present invention illustrating variousobjects and features thereof.

FIG. 1 illustrated an exploded perspective view of one embodiment of theinvention.

FIG. 2 illustrates a perspective view of one embodiment of theinvention.

FIG. 3 illustrates a side view of one embodiment of the invention in useloaded with particulate material.

FIG. 4 illustrates a side view of an embodiment of the inventionincluding unloaded particulate material.

FIG. 5 illustrates a front perspective view of an embodiment of theinvention in a trailer including a reciprocating slat conveyor.

FIG. 6 illustrates a rear view of an embodiment of the invention in atrailer including a reciprocating slat conveyor.

FIG. 7 illustrates a rear perspective view of a trailer including areciprocating slat conveyor and an embodiment of the invention havingunloaded particulate material.

FIG. 8 is a perspective view illustrating an embodiment of the presentinvention placed on top of a reciprocating slat conveyor.

FIG. 9 is a perspective view illustrating an embodiment of the presentinvention placed on top of a reciprocating slat conveyor beginning anunload cycle.

FIG. 10 illustrates an embodiment of the present invention placed on topof a reciprocating slat conveyor at the end of an unload cycle, whereina first group of reciprocating slats is retracted.

FIG. 11 is a perspective view illustrating an embodiment of the presentinvention placed on top of a reciprocating slat conveyor at the end ofan unload cycle, wherein a second group of reciprocating slats isretracted.

FIG. 12 is a perspective view illustrating an embodiment of the presentinvention placed on top of a reciprocating slat conveyor at the end of aan unload cycle, wherein a third group of reciprocating slats isretracted.

FIG. 13 is a side elevation of an embodiment of the present invention,illustrating a winch mounted to a wall structure of a trailer connectedto the invention embodiment via a tether.

FIG. 14 is a rear elevation of an embodiment of the present invention,illustrating the attachment of a tether bar to the embodiment.

FIG. 15 is a perspective view of an alternative embodiment of thepresent invention, illustrating the base flange locked against a panelsweeper face.

FIG. 16 is a perspective view illustrating an alternative embodiment ofthe present invention, illustrating a panel sweeper face includingratchet straps.

FIG. 17 is a detailed perspective view taken about the circle of FIG.16.

FIG. 17A is a partial elevational view thereof.

FIG. 18 is a perspective view thereof, showing the base flange lockedagainst a panel sweeper face with ratchet straps.

FIG. 19 is a side elevational view of an alternative embodiment of thepresent invention showing a releasable restraining chain.

FIG. 20 is a perspective view of an alternative embodiment of thepresent invention including an extension panel above the panel sweeperface.

FIG. 21 is a side elevational view thereof.

FIG. 22 is a rear elevational view of an alternative embodiment of thepresent invention including locking plates.

FIG. 23A is a side elevational view of the prior art thereof.

FIG. 23B is a side elevational view thereof, showing elements of theprior art in a tipping state.

FIG. 23C is the alternative embodiment thereof, showing elements ofpresent invention in a tipping state.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Introduction and Environment

As required, detailed aspects of the present invention are disclosedherein, however, it is to be understood that the disclosed aspects aremerely exemplary of the invention, which may be embodied in variousforms. Therefore, specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as a basis forthe claims and as a representative basis for teaching one skilled in theart how to variously employ the present invention in virtually anyappropriately detailed structure.

Certain terminology will be used in the following description forconvenience in reference only and will not be limiting. For example, up,down, front, back, right and left refer to the invention as orientatedin the view being referred to. The words, “inwardly” and “outwardly”refer to directions toward and away from, respectively, the geometriccenter of the aspect being described and designated parts thereof.Forwardly and rearwardly are generally in reference to the direction oftravel, if appropriate. Said terminology will include the wordsspecifically mentioned, derivatives thereof and words of similarmeaning.

The present invention features an ejector system 2 which mounts withinan existing trailer 4 and is used to unload material from within thattrailer. The present invention may be included in new trailers as acomplete ejector trailer system, or it may be retrofitted into existingtrailers implementing a “moving floor” or reciprocating slat floorsystem.

II. Preferred Embodiment or Aspect Ejector Trailer System 2

The embodiments discussed herein are merely illustrative of specificmanners in which to make and use the invention and are not to beinterpreted as limiting the scope of the instant invention.

Referring to the drawings in detail, FIG. 1 illustrates an explodedperspective view of one embodiment of the invention. A rectangular basemember 100 with support members 200 mounted thereon supports the panelsweeper 300. In the preferred embodiment, the base and support membersare made of aluminum; the base and support members may, however, beformed of any other appropriate material capable of achieving thedesired form and performing the desired function including, but notlimited to, plastic, metal, or wood. In the preferred embodiment thepanel sweeper is sheet metal; the panel sweeper may, however, be formedof any other appropriate material capable of achieving the desired formand performing the desired function including, but not limited to,plastic, metal, or wood.

A base flange 400 and two side flanges 500 are mounted onto the panelsweeper at the bottom and sides of the panel sweeper respectively. Thesurface of the base flange 400 may be of any area up to and includingthe same area of the panel sweeper 300 face. In the preferredembodiment, the flanges are made of rubber; the flanges may, however, beformed of any other appropriate material capable of achieving thedesired form and performing the desired function. This allows theejector system 2 to handle material 6 of a high moisture content, asshown in FIGS. 3 and 4, such as wood pulp, corn, mulch, grain, orsimilar products which otherwise would tend to stick to the floor andwalls 5 of the trailer 4.

In the present embodiment, the flanges are mounted onto the panelsweeper via a plate and screw assembly 600; the flanges may also bemounted by any other appropriate means including, but not limited to aplate and rivet assembly, adhesives, or mounting the flanges between thepanel sweeper and support members. A means for traversing the panelsweeper may include an access door 700, such as a hinged door, ahorizontally sliding panel, or a vertically sliding panel and providesaccess to the trailer area behind the apparatus without the need toclimb over the apparatus and risk injury. A tether bar 800 is mountedbetween the support members. In an alternate embodiment, the tether barmay be mounted on the back portion of the panel sweeper itself. In thepreferred embodiment, the tether bar is made of aluminum; the tether barmay, however, be formed of any other appropriate material capable ofachieving the desired form and performing the desired functionincluding, but not limited to, plastic, metal, or wood.

FIG. 2 illustrates a perspective view of one embodiment of the inventionin its assembled state.

FIG. 3 illustrates the invention in the bed of a self-unloading trailer4 that has been filled with material 6 in a position ready to beunloaded. The trailer employs a moving floor system 8 comprised of anumber of moving floor slats 10, such as that provided by the Keith®Walking Floor® system of Keith Mfg., Co. of Oregon, USA. This movingfloor system 8 causes the entire load 6 and the ejector system 2 to movetoward the open end of the trailer 4, thereby causing the load 6 to beejected from the trailer. The ejector system 2 ensures that the entireload 6 is ejected, even if that load is comprised of high-moisturecontent material.

FIG. 4 illustrates the invention in the bed of a self-unloading trailerand in the process of ejecting material therefrom. FIGS. 5-7 illustrateadditional views of the invention in the bed of a self-unloading trailerand in use. The ejector system 2 is moved along the internal space ofthe trailer 4 by the moving floor system 8 in the direction of the arrow16.

FIGS. 8 through 12 demonstrate a method of using the ejector system 2mounted within a trailer fitted with a reciprocating slat conveyorsystem 8. The conveyor system 8 is comprised of a number ofreciprocating slats 10, capable of moving both the ejector system 2 andthe material 6 loaded in the trailer 4. The reciprocating floor system 8physically moves the ejector system 2 toward the open end of the trailer4, thereby pushing the loaded material 6 out of the trailer.

FIG. 9 shows the beginning of an unloading process, whereby the variousreciprocating slats 10 are moved toward the open end of the trailer,thereby advancing the ejector system 2 and any material 6 loaded withinthe trailer 4. FIGS. 10-12 represent the retraction of the various slats10, leaving the ejector system 2 and the loaded material 6 in place forthe next unloading step as again shown in FIG. 9, whereby each of thereciprocating slats moves rearward and further advances the ejectorsystem 2 and the loaded material 6. This process continues until thematerial 6 is completely unloaded from the trailer 4. At this point theejector system 2 is situated near the open end of the trailer.

FIGS. 13 and 14 show the tether bar 800, tether 12, and winch 14elements in more detail. The winch 14 is mounted to the end wall 7 ofthe trailer 4. An optional pulley 17 may also be mounted to the end wall7 if desired or necessary. The tether bar 800 is mounted to a pair ofupstanding vertical supports 20 connected to the structural supports 200of the ejector system 2. The tether bar 800 is affixed to the support 20using a nylon strap 18 on either end, or some other means of temporarilyaffixing the tether bar to the supports, such as a nut 22 and bolt 23arrangement shown in FIG. 14. A U-bolt fastener 21 passes through thetether bar 800 to attach the tether 12 securely to the tether bar.Alternatively, the tether bar 800 could be mounted to the existingsupports 200.

After a load 6 has been completely emptied from the trailer 4, the winch14 and tether 12 pull the ejector system 2 back to its starting positionat the end wall 7 of the trailer. During this retraction phase, if theejector system 2 encounters an obstruction or material which has somehowwound up between the ejector 2 and the end wall 7 of the trailer, theejector system will tip over rearwards (toward the end wall 7 of thetrailer). This feature accomplishes three things; (1) it notifies theuser that an obstruction is present; (2) it prevents the obstructionfrom jamming between the ejector 2 and the trailer 4; and (3) it allowsthe user quick access to remove the obstruction.

If the ejector system 2 tips over and the obstruction is removed, theejector may be tipped back to its upright position or it may beretracted while laying down. If it is retracting while laying down, thetether 12 will pull the ejector system 2 back to its vertical startingposition upon reaching the starting position. A plastic flange may beaffixed to the bottom surface of the rectangular base member 100 toreduce friction between the ejector system 2 and the reciprocating slats10 while the ejector system is being retracted.

As stated previously, this system is suited for bulk flowing materials.These flowing materials tend to stick to the surfaces of trailers duringnormal unloading processes. The reciprocating floor combined with theejector system 2 including the floor flange 400 and wall flanges 500allows the present system to produce a better method for ejectingflowing material from a trailer. The flanges actively remove residualmaterial from the walls and floor while the load is ejected, therebynegating much of the necessity to clean the trailer out between loads.This results in a more efficient unloading process.

III. Alternative Embodiment: Locking Base Flange 402

In an alternative embodiment of a ejector system 52, the user may opt toload a trailer 4 with a load that protrudes above the top of trailerwalls 5, thus potentially causing materials to lodge between top offloor & crossbows connecting trailer walls, forcing materials behind theejector system 52 while it travels underneath the crossbows, such aswith a load of tree limbs. In such an instance, the user may fold theflange 402 up against the panel sweeper 300 and lock the flange in placeusing a locking mechanism 54, such as a pair of tabs.

Because of the flexible nature of the base flange 402, the flange couldsimply be tucked under a pair of tabs 54, as shown in FIG. 15. Theflange 402 may be of any size including having a surface area up to andequal to the surface area of the panel sweeper face 300. Alternatively,the flange could be snapped to the panel sweeper face 300 with some sortof temporary snapping means. Another alternative includes magneticallyaffixing the flange to the panel sweeper face. It is necessary that theflange 402 remain locked against the face 300 during the entireunloading process of the material which may otherwise jam underneath ofthe flange. After unloading, the locking means 54 must quickly releasethe flange 402 for the next load, if it is needed.

An alternative system for lifting and locking the base flange 402includes a fully adjustable winch and strap system with a hook, whereinthe hook engages the base flange 402 to sweeper panel 300 to keep in anupright locked & loaded position. The winch lifts the flange and securesit in place, and is further capable of lowering the flange 402 back intoits original position when desired. A number of winches may be used,wherein the straps and hooks are affixed to the flange at various pointsalong the length of its front end.

IV. Alternative Embodiment Side Panel Protectors 104 and/or RatchetStraps 106 with Hooks 108

FIGS. 16, 17, 17A, and 18 show an alternative embodiment of the aboveinvention including side panel protectors 104. These panel protectorsare ideally manufactured from ultra-high molecular weight (UHMW)plastic, or a similar composite, for low-friction and high-resilience.The purpose of the protectors 104 is to prevent the trailer walls fromcoming into contact with the headboard, coupled with unloading thetrailer on un-even terrain, which tends to cause over-rotation of theejector system 2 within the confines of the trailer 4 as the systemoperates. Most trailers are designed to flex (also referred to as“racking”). While doing so, the protectors 104 keep forceful engagementwith the headboard, thus preventing damage to the outer walls. The panelmay tend to tilt perpendicular to the forward and backward movement ofthe ejector system, which could cause the structural elements 100, 200,500 of the sweeper to come into contact with the side walls 5 or roof ofthe trailer 4, damaging one or both pieces of equipment. The protectors104 ensure that the panel cannot rotate further than a few degrees, asshown by FIG. 17A, and are manufactured from suitable materials toprevent the panel from buckling or pivoting when contact with the wallsdoes occur.

FIGS. 16 and 18 also feature hooks 108 suspended from ratchet straps 106which may connect with receivers 112 of the base flange 400, similar tothe concept shown in FIG. 15. However, the previous embodiment disclosedin FIG. 15 tends to allow the flexible base flange 400 to sag in themiddle, which could cause material to be caught between the saggingflange 400 and the face 300 of the sweeper panel. The ratchet straps 106are connected to a rigid beam 110 or other structural element and allowthe straps to be pulled tight, thereby removing the flexing of the baseflange 400 and preventing material from being forced between the flangeand the sweeper panel face 300. The receivers 112 may simply be holeswithin the base flange, or they may be protected holes, such as metalrings passing through the flange, or they may be other structuralelements affixed to the top face of the flange 400. Otherwise, once theflange 400 is pulled tight against the face 300 of the sweeper, thesystem functions similarly to the embodiment disclosed above and in FIG.15.

V. Alternative Embodiment Releasable Restraining Chain 124 and Hook 122

FIG. 19 features an alternative embodiment of the ejector system 2 whichincludes a restraining chain 124 affixed to the structural support ofthe ejector, such as the vertical supports 20. The chain terminates in areleasable hook 122, such as a carbineer, a hook with a hinged safetylatch, or a hook with a threaded safety latch. The hook 122 can connectto a receiver 120, such as an eyehook, connected to the front wall 7 ofthe trailer 4. This prevents the ejector system 2 from moving away fromthe front wall 7 when unloading the trailer or when on a tippingplatform or hauling other debris (e.g. tree limbs) which may protrudeover the top of the side walls of the trailer. It also prevents theejector system 2 from tipping or moving while the trailer 4 is intransport or if there are high winds.

VI. Alternative Embodiment with Extension 302

FIGS. 20 and 21 show an alternative embodiment ejector system 2 havingan extension 302 placed above the sweeper panel face 300 to increase thecapacity of the ejector system 2, allowing the system to move morematerial loaded into the trailer 4. As shown, the extension extendsabove the original sweeper panel face 300. The extension may be anyshape, but is shown having a slight arc to correspond with an amount ofmaterial as it would typically appear within a trailer. Supports 304hold the extension 302 up, and may be bolted or otherwise temporarily orpermanently affixed to the supports of the original ejector system 2.

Alternatively, the extension 302 may be connected directly to thesweeper panel face 300, such as via screws or other fasteners. Thisessentially places the extension against the sweeper panel face 300, butthe extension 302 will extend above where the original face 300extended.

VII. Alternative Embodiment with Locking Panels 356

FIGS. 22-23C disclose an alternative embodiment ejector system includinglocking panels 356 as distinguishable from the previously disclosedejector system 2 without locking panels. FIGS. 22 and 23C disclose thealternative embodiment, whereas FIGS. 23A and 23B disclose the previousembodiment and prior art.

In FIG. 22 the locking panels 356 are shown as rectangular platespivoting about a pivot point, such as a bolt. These panels lock in avertical orientation such that they are in proximity with the headboards352 of the trailer 4 side walls. When the panels are in an unlockedorientation 358, the entire ejector system can be tilted forward toclean material from behind the panel; however, when locked in the lockedposition as indicated by 356, the panel cannot tilt past the headboards352, as shown in FIG. 23C. The locking panels either directly come intocontact with the headboards 352 or they come into contact with astopping element affixed to those beams (not shown).

FIGS. 23A and 23B show what happens if the ejector system is allowed totilt freely. Sometimes high winds can cause the ejector system 2 to tiltforward, as shown in FIG. 23B, without the operator desiring that motionto occur. This can damage equipment or cause potential injuries to theoperator. However, the ability for the entire ejector system 2 to tiltforward for cleaning purposes is desirable, so the alternativeembodiment shown in FIGS. 22 and 23C is preferred.

It is to be understood that while certain embodiments and/or aspects ofthe invention have been shown and described, the invention is notlimited thereto and encompasses various other embodiments and aspects.

Having thus described the invention, what is claimed as new and desiredto be secured by Letters Patent is:
 1. An ejector system for a trailerincluding two side walls, a floor structure, a front end, a rear end andan interior space formed by said sidewalls and said floor structure,said interior space being adapted to receive contents for ejecting fromsaid trailer, which ejector system includes: said floor structureincluding a reciprocating floor system adapted for advancing contents ofsaid interior space towards said trailer rear end; an ejector includinga structural frame, a sweeper panel, a pair of side flanges and a baseflange adapted for engaging said trailer and said interior space; saidejector being movable between front and rear positions by saidreciprocating floor; said ejector flange being adapted for removingcontents from said interior space as said ejector moves from its frontposition to its rear position; said side flanges and said base flangecomprised of a flexible material; said side flanges forming a sealbetween said sweeper panel side edges and said trailer side walls; saidbase flange configured to travel with said ejector from said front tosaid rear positions in a first, generally horizontal transport positionwherein said material is at least partially located on top of said baseflange; said base flange configured to flex downward into a second,unloading position upon reaching the rear end of said trailer, such thatmaterial is caused to slide off of said flange adjacent to said rear endof said trailer; a plurality of ratchet straps each having a first endaffixed to said sweeper panel and each having a second end terminatingin a hook; said base flange including a respective plurality of receiverholes each corresponding to one of said plurality of ratchet strapshooks; and said plurality of ratchet straps configured to selectivelydraw said base flange flush with said sweeper panel.
 2. The ejectorsystem of claim 1, wherein: said sweeper panel width conforms to thewidth of the interior space of said trailer as defined by said two sidewalls; and said sweeper panel height conforms to the height of theinterior space of said trailer.
 3. The ejector system of claim 1,further comprising: a locking mechanism affixed to said sweeper panel;and said locking mechanism adapted for restraining said base flangeflush against the front face of said sweeper panel.
 4. The ejectorsystem of claim 1, further comprising a low-friction plate affixed tosaid structural frame, said plate adapted to provide low-frictioncontact between said ejector and said reciprocating floor.
 5. Theejector system of claim 1, further comprising: an opening in saidsweeper panel adapted for providing access to the area of the trailerpositioned behind said sweeper panel; and a door affixed to said sweeperpanel, said door capable of selectively blocking said opening.
 6. Theejector system of claim 1, further comprising: an adjustable tether baraffixed to said structural frame of said ejector; a winch affixed to thefront end of said trailer; and a tether connecting said tether bar tosaid winch, whereby said winch is capable of pulling the ejector to astarting position located in proximity to said trailer front end.
 7. Theejector system of claim 6, wherein said ejector will tip backwardstoward the front end of said trailer if said ejector comes into contactwith an obstruction while said winch is actively pulling said ejector.8. The ejector system of claim 1, further comprising: a restrainingchain affixed to the front end of said trailer, said restraining chainterminating in a releasable hook; a receiver affixed to said ejectorstructural frame; and said restraining chain configured to restrain saidejector in proximity to said front end of said trailer.
 9. The ejectorsystem of claim 1, further comprising: an extension configured to beplaced above said sweeper panel, said removable extension comprising afront face configured to be generally along the same plane as saidsweeper panel and supports configured to hold said extension panel inplace; and said extension extending above the two side walls of saidtrailer.
 10. The ejector system of claim 9, wherein said extension isselectively removable.
 11. The ejector system of claim 9, wherein saidejector panel comprises a top edge having a generally arcuate shape. 12.The ejector system of claim 1, further comprising: a pair of lockingpanels, each locking panel pivotally mounted to a respective headboardof said two side walls of said trailer; said pair of locking panelsconfigured to be rotated between a first, locked position and a second,unlocked position; wherein said locking panels are configured torestrict said ejector from tipping within said trailer when said lockingpanels are in said first, locking position; and wherein said ejector isfree to tip over when said locking panels are in said second, unlockedposition.